loose wires

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Johnny Grand

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I came across loose wires at the bulkhead. Both heavy wires with the screws in them. The screws are tight but the wire/spade can be pulled out and pushed in from the bulkhead piece. It is a 63, supposedly a stronger connection on these vehicles than others. Makes me nervous. I feel things should be tight. Any thoughts?.
 
The pieces that are loose are solid metal pieces that go through the bulkhead plastic connector so I'm sure "you are good" so long as the terminals / wire crimps/ screw terminals are all corrosion free and tight. "I wish to heck" Ma had stayed with those instead of what most of use are saddled with

I had to perform my first bulkhead connector repair while in the Navy in the early 70's on my own 70 440-6 RoadRunner. "I will admit that both the previous owner and I were radio amateurs, and both of us had equipment in the car at times. The bulkhead connector was badly overheated. "Back then" I just ran paired no12's through enlarged holes in the connector.
 
Thanks. Yes the screws are tight but again the spade part will slide in and out of the plastic bulkhead. It just does not seem right to me to be able move an electrical connection. If the spade is pulled to the engine side wouldn't it pull out from the under dash side?
 
Johnny Grand said:
Thanks. Yes the screws are tight but again the spade part will slide in and out of the plastic bulkhead. It just does not seem right to me to be able move an electrical connection. If the spade is pulled to the engine side wouldn't it pull out from the under dash side?
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The thing is on those cars you have a solid piece of metal going through the "connector." The solid piece is loose in the plastic. The wire connections at each end so long as they are "good" to the metal are fine. I don't know how loose you are "saying" will they pull/ fall clear out? That might be a "short" issue, otherwise maybe some sealer RTV/ rubber cement etc to firm them up some
 
Thanks for the replies guys. Yes, it is the solid spade piece moving in and out in the plastic. I will have to look under the dash side and check the connection there. I figure that is why you sent new terminal links. Thanks for that. The spade probably moves 1/8 inch maybe 3/16. Enough to make you go huh!
 
Man guys, that wiring on these old cars are ancient. Time to step up and buy a new harness. I just got done with mine. Now, the motor fires up and the headlights are a lot brighter. Next wiring mod is to install one of Crackedback’s HL relay harnesses.
 
slantsixdan said:
Packard 59 terminals

Packard 56 terminals
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No Dan. He's talking about the R6 and A1 wires that have an captive (forked) spade or ring terminal that is clamped to the connector terminal.

You can see that here.
img_20190603_145929355-jpg.jpg

The spade (some call it a buss bar) going through the connector is loose, then you will want to secure it.
The more it moves around, the more chance of breaking wire strands in the crimps.

Its could be loose because it was physically hit, or because it saw a lot of current and the plastic was damaged from the heat. High currents come from events like recharging a dead battery with the alternator and such.
Another reason it could have become hot would be a poor connection either at the clamped terminal or inside at the wire crimp.

Here is an example where one was damaged.
upload_2021-2-14_20-32-8-png.png


pxl_20210215_010032073-jpg.jpg


If you go to that thread, you'll see on that car, the ammeter also was damaged by overheating.
Anyone Know What this Connector is Called?

That could have been from years of use with a loose connection, excessively high charging rate and ignoring the ammeter needle, or a short to ground.
 
Thanks Mattax, the third picture shows what I am seeing from the engine side. Again, The screw/bolt is tight to the spade, but that spade is moving in and out of the housing. Not out of the plastic but moving as mentioned above. I have not been able to get under the dash yet but the damaged picture looks as if the dash side just has a crimped wire to it. That's what concerns me!. How would this spade be secured. Nothing looks damaged at least from the dash side.
 
It looks to me like plastic suround was molded to the metal spade. My guess is those two spades were then crimped and to the wires and finally snapped into the big plastic housing. I don't think they were meant to be removed. If you used an epoxy, that might hold it. If you go that route my suggestion is use the just enough to hold it in place and seal the cavity. My thinking here is that if it get hot, the more filler, the more difficult it will be for the heat to transfer away.

You may already know this, but both of those big wires are always electricly hot, even when the key off. Disconnect the battery when working on them with metal tools (or if wearing something like a wedding ring)
 
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